Ceramic turbine blade attachment having high temperature, high stress compliant layers and method of fabrication thereof

ABSTRACT

A nickel base single crystal compliant layer on a ceramic blade has the capability to sustain high stresses and high operating temperature. Layers of nickel and platinum bonded on a single crystal superalloy over a sputtered gold-chromium layer support the high stress levels at elevated temperature without extrusion of the soft platinum or nickel layer and without destruction of an NiO compliant surface. The compliant layers have survived stress and temperature conditions without failure to the ceramic blade and the system can be stressed/heated and unloaded/cooled repeatedly without damage to the ceramic blades. A single crystal nickel base superalloy (i.e., SC180) has high strength properties at elevated temperature. Thin layers of chromium followed by gold are e-beam evaporated on one side of a polished surface of the alloy. Pure nickel is electroplated over this e-beam gold-chromium layer. Platinum is either electroplated or plated electrolessly over the nickel layer. The structure is annealed in vacuum or inert atmosphere to allow the diffusion of gold-chromium alloy into the superalloy and permit the nickel layer and diffusion of nickel into platinum to form a multilayer structure which is metallurgically bonded. The sheet is oxidized in air to allow diffusion of the nickel layer through the platinum to come to the surface and oxidize forming nickel oxide. This nickel oxide layer acts as the load distribution layer which does not extrude and the structural integrity of the compliant layer is maintained by the high-strength single crystal superalloy.

CROSS REFERENCE TO RELATED APPLICATION

The present application is a divisional of U.S. patent application Ser.No. 09/886,757, filed Jun. 20, 2001 now U.S. Pat. No. 6,602,548.

BACKGROUND OF THE INVENTION

The present invention generally relates to turbine blades and, moreparticularly, to compliant layers employed to attach turbine blades to adisk.

Gas turbine power plants are used as the primary propulsive power sourcefor aircraft, in the forms of jet engines and turboprop engines, asauxiliary power sources for driving air compressors, hydraulic pumps,etc. on aircraft, and as stationary power supplies such as backupelectrical generators for hospitals and the like. The same basic powergeneration principles apply for all of these types of gas turbine powerplants. Compressed air is mixed with fuel and burned, and the expandinghot combustion gases are directed against stationary turbine vanes inthe engine. The vanes turn the high velocity gas flow partially sidewaysto impinge upon turbine blades mounted on a turbine disk or wheel thatis free to rotate.

The force of the impinging gas causes the turbine disk to spin at highspeed. Jet propulsion engines use this power to draw more into theengine and then high velocity combustion gas is passed out the aft endof the gas turbine, creating forward thrust. Other engines use thispower to turn a propeller or an electric generator.

The turbine blades and vanes lie at the heart of the power plant, and itis well established that, in most cases, they are one of the limitingfactors in achieving improved power plant efficiency. In particular,because they are subjected to high heat and stress loadings as they arerotated and impacted by the hot gas, there is a continuing effort toidentify improvements to the construction and/or design of turbineblades to achieve higher performance.

Much research and engineering has been directed to the problem ofimproved turbine blade materials. The earliest turbine blades were madeof simple cast alloys having relatively low maximum operatingtemperatures. The alloy materials have been significantly improved overa period of years, resulting in various types of nickel-based andcobalt-based superalloys that are in use today.

Ceramic blades (Si3N4) are used when a turbine needs to be run atelevated temperatures to improve the efficiency and performance ofturbine engines. However, ceramic blades need to be inserted intometallic turbine disks. Because ceramic blades are susceptible tofracture by local point loading, a compliant layer is needed toredistribute the ceramic blade loading. As the ceramic is operated athigh temperature and high speeds in a turbine, a compliant layer isneeded which supports the loading without extrusion or creeping and yetplastic or soft enough to redistribute the loading at the ceramiccompliant layer interface. At each engine cycle, the blade must partfrom the metallic turbine disk to accommodate the thermal expansiondifferences between ceramic and metal to prevent crushing of the bladeroot.

U.S. Pat. No. 6,132,175 for Compliant Sleeve For Ceramic Turbine Bladesdiscloses the use of a compliant layer fabricated from a cobalt-basedlow temperature capable superalloy which is bonded to a thin layer ofnickel and platinum. The structure is oxidized to form a NiO surface,which contacts the ceramic blade. The compliant layer is lubricated withBN (Hexagonal Boron nitride) and sputtered gold.

U.S. Pat. No. 6,127,048 for Article Of Manufacture Having A MetalSubstrate With An Oxide Layer And An Improved Anchoring Layer And MethodOf Bonding The Same describes the formation of anchored thermal barriercoating on ceramic blades. It uses an anchoring layer primarily madefrom ternary oxides. The '048 patent does not relate to a compliantlayer. Essentially, the blades which need to be protected from thermalconditions of the engine are coated with thermal barrier layers. Thispatent suggests that intermediate ternary oxides improve the bonding ofthe zirconia thermal barrier coating. The disclosed blade has coatingsof low thermal conductivity oxides that do not provide the requiredcompliance and durability on repeated cycling (both thermal andmechanical movement) needed for the present application.

U.S. Pat. No. 6,066,405 for Nickel-Base Superalloy Having An OptimizedPlatinum-Aluminide Coating uses a platinum-aluminum coating overmetallic blades and may use a ceramic thermal barrier coating over theblade. This patent is similar to the previous patent disclosing athermal barrier coating for metallic turbine blades. This has nothing todo with compliant layers for ceramic blade attachment. Platinumaluminide is an intermetallic compound and lacks the ductility ofplatinum and, thus, will not provide the required compliance and loaddistribution characteristics needed to support a ceramic blade. Theceramic thermal barrier coating is also very hard and if it comes incontact with a ceramic blade, it will shatter it due to localizedloading.

U.S. Pat. No. 5,712,050 for Superalloy Component WithDispersion-Containing Protective Coating describes a coating for asuperalloy article which is a nickel based superalloy containingdispersoids of oxides of yttrium, hafnium and or a rare earth. Thecoating protects the superalloy body from oxidation, fatigue, etc. Thispatent describes a protective coating on superalloy articles such asblades and has nothing to do with compliant layers. If a similar coatingwere used for compliant layers, it would not work because the nickelbased superalloy with dispersoids lacks the compliance and the hardparticles will produce localized contact on the ceramic blade creatingpoint loading and fracture.

What is still needed is a compliant layer coating for a ceramic turbineblade wherein the layer is capable of operating at higher temperaturesand levels of stress in an oxidizing environment.

SUMMARY OF THE INVENTION

The present invention resides in the use of a nickel based singlecrystal compliant layer on a ceramic blade, which has the capability tosustain the high stresses at high operating temperatures, but theproperties of such a layer are easily degraded by contamination as wellas nucleation of secondary grains. The high stresses applied at hightemperature can easily squeeze out the thin layers of soft metals suchas platinum and nickel. When this happens, the nickel oxide layergenerated will break and disappear on subsequent loading and unloadingcycles. The invention exploits the discovery that layers on nickel andplatinum bonded on a single crystal superalloy over a sputteredgold-chromium layer can indeed support the high stress levels atelevated temperature without extrusion of the soft platinum or nickellayer and without destruction of an NiO compliant surface. The compliantlayers have survived stress and temperature conditions without failureto the ceramic blade and the system can be stressed/heated andunloaded/cooled repeatedly without damage to the ceramic blades.

A high strength superalloy is employed due to its single crystal natureand a coating is used which does not degrade the single crystal alloy,yet provides sufficient compliance to support the ceramic blade underconditions of high stress (such as about 50 Ksi to 100 Ksi) and hightemperature (such as about 760° C. to 875° C.). The blade is releasedwithout bond formation on each cycle so that, during cooling, the bladeis not crushed by the dove tail slot due to the large thermal expansioncoefficient of the metallic disk alloy compared to the silicon nitrideceramic blade.

This invention may use a single crystal nickel base superalloy (e.g.,SC180) which has high strength properties (e.g., about 60 Ksi to 160 Ksiyield depending on orientation) at elevated temperature (e.g., about760° C. to 875° C.). Thin layers of chromium followed by gold are e-beamevaporated on one side of a polished surface of the alloy. Pure nickelis electroplated over this e-beam gold-chromium layer. Platinum iseither electroplated or plated electrolessly over the nickel layer. Thestructure is annealed in vacuum or inert atmosphere to allow thediffusion of gold-chromium alloy into the superalloy and permit thenickel layer and diffusion of nickel into platinum to form a multilayerstructure which is metallurgically bonded. The sheet is oxidized in airat about 900 to 1000° C. to allow diffusion of the nickel layer throughthe platinum to come to the surface and oxidize, forming nickel oxide.This nickel oxide layer acts as a load distribution layer, which doesnot extrude and the structural integrity of the compliant layer ismaintained by the high-strength single crystal superalloy.

These and other features, aspects and advantages of the presentinvention will become better understood with reference to the followingdrawings, description and claims.

BRIEF DESCRIPTION OF THE DRAWINGS

FIGS. 1-7 are respective micro-photographs of a sample of an embodimentof the present invention;

FIG. 8 is an integrated graph of linescan results near the surface ofthe sample of FIGS. 1-7;

FIG. 9 is a series of separate graphs of the linescan results of FIG. 8,but showing the individual coating materials; and

FIG. 10 is a micro-photograph of an oxidized SC-180 compliant layer inaccordance with the invention.

DETAILED DESCRIPTION OF THE INVENTION

The following detailed description is the best currently contemplatedmodes for carrying out the invention. The description is not to be takenin a limiting sense, but is made merely for the purpose of illustratingthe general principles of the invention.

The present invention may employ about a 0.005 thousands of an inch to0.020 thousands of an inch thick single crystal nickel base superalloysuch as SC180 (described in EPO Patent Application No. 246,082 andincorporated herein by reference), which has high strength properties(about 160 Ksi) at elevated temperature (about 1400° F., 760° C.). Thinlayers (e.g., about 0.0012 thousands of an inch to 0.0032 thousands ofinch and preferably about 0.002 thousands of an inch) of chromiumfollowed by gold (about 0.02 thousands of an inch to 0.04 thousands ofan inch and preferably 0.032 thousands of an inch thick) can be e-beamevaporated on one side of a polished surface of the alloy. Pure nickelcan be electroplated to a thickness of about 0.0012″ to 0.0018″, andpreferably about 0.0015″, over this e-beam gold-chromium layer. Platinummay be either electroplated or plated electrolessly over the nickellayer to a thickness of about 0.0004″ to 0.0007″, and preferably about0.0005″.

The structure can be annealed at about 800° C. to 925° C., andpreferably about 900° C., for about 0.4 to 0.6 hours, and preferablyabout 0.5 hours, in vacuum or inert atmosphere to allow the diffusion ofgold-chromium alloy into the superalloy and nickel layer and diffusionof nickel into platinum to form a multilayer structure which ismetallurgically bonded. The sheet can be oxidized in air at about 950°C. to 1050° C., and preferably about 1000° C. for about 0.75 to 1.25hours, and preferably about 1 hour, to allow diffusion of the nickellayer through platinum to come to the surface and oxidize, forming anickel oxide of about 0.0003″ to 0.0006″, and preferably about 0.0004″.This nickel oxide layer acts as a load distribution layer, which doesnot extrude and the structural integrity of the compliant layer ismaintained by the high-strength single crystal superalloy.

EXAMPLE

A single crystal superalloy sheet of SC 180 (0.009″ thick) wasmechanically polished first to remove cutting damage and the thicknesswas reduced to 0.006″ to 0.007″. It was then cleaned with a mixture ofammonium hydroxide and hydrogen peroxide. One side of the superalloysheet was coated to a thickness of about 0.002 thousands of an inchchromium and about 0.032 thousands of an inch gold by e-beamevaporation. The backside was masked and nickel was electroplated from aWatt's bath to a thickness of about 0.0015″ and platinum waselectroplated over the nickel layer to a thickness of about 0.0005″. Themask was removed and the multilayer superalloy sheet was annealed atabout 900° C. for about 0.5 hours in evacuated and argon back filledatmosphere to allow diffusion and metallurgical bond formation. Thestructure was oxidized in air at about 1000° C. for about 1 hour togenerate a NiO layer over the platinum layer by diffusion of nickelthrough platinum to the free surface where it oxidizes freely.

FIGS. 1-7 are microphotographs of the resulting diffusion profiles forthe above example in the unoxidized state. FIGS. 1 and 2 are atmagnifications of 50× and 200×, respectively, with the sample unbent.FIGS. 3 and 4 are at magnifications of 50× and 200×, respectively, withthe sample sheet bent in the direction of the coated side. FIGS. 5 and 6are at magnifications of 50× and 200×, respectively, with the samplesheet bent in the opposite direction. FIG. 7 is a 1500× magnificationmicrophotograph of the bent area. The microphotographs of FIGS. 1-7 showno delamination in the bent region and virtually no surface cracking,even at a magnification of 1500×.

FIGS. 8 and 9 illustrate EDX linescan results on an integrated graph andon separate graphs, respectively, showing the relative amounts of Ni,Pt, Au and Cr over a 47 μm distance through the coating toward the freesurface for the above example. It can be seen that the outermost area(right) comprises both nickel and platinum, but thereafter the nickelquickly becomes predominant toward the left. The gold and chromium arepresent in relatively small amounts along the entire scanned line. Theprofile illustrates the diffusion of the nickel through the platinumtoward the free surface.

FIG. 10 illustrates the oxidized SC-180 compliant layer from thesuperalloy up through the diffused and oxidized nickel outer layer.

It will be understood that the present invention has been disclosedherein in the form of a preferred embodiment. Moreover, it will beunderstood that although precise layer thickness, temperature and otherparameters have been defined for each step of the coating processdisclosed, these parameters may be readily altered while still achievingthe advantageous results described herein.

Thus, the scope of the invention hereof is to be limited only by theappended claims and their equivalents.

We claim:
 1. A ceramic blade for turbines, the blade having a compliantlayer coating attachment comprising: a single crystal superalloy;evaporated layers of chromium and gold on one side of said superalloy; aplated layer of nickel over said chromium and gold; and a plated layerof platinum over said nickel layer.
 2. The blade coating recited inclaim 1, wherein the superalloy is nickel-based and has a thickness inthe range of about 5 to 20 thousands of an inch.
 3. The blade coatingattachment recited in claim 1, wherein said layer of nickel has athickness in the range of about 1.2 to 1.8 thousands of an inch.
 4. Theblade coating attachment recited in claim 1, wherein said layer ofplatinum has a thickness in the range of about 0.4 to 0.7 thousands ofan inch.
 5. The blade coating attachment recited in claim 1, whereinsaid layers of chromium and gold have a thickness in the range of about0.0012 to 0.0032 thousands of an inch and about 0.02 to 0.04 thousandsof an inch, respectively.
 6. The blade coating attachment recited inclaim 1, further comprising a diffusion of said nickel layer into saidplatinum layer.
 7. The blade coating attachment recited in claim 6,further comprising a load distribution layer of nickel oxide formed fromoxidation of said diffused nickel.
 8. The blade coating attachmentrecited in claim 1, wherein said nickel is diffused through saidplatinum to form a nickel oxide surface to provide a load distributionlayer for supporting said ceramic blade.
 9. A ceramic blade forturbines, the blade having a compliant layer coating attachmentcomprising: a single crystal nickel base superalloy; evaporated layersof chromium and gold on one side of said superalloy; a plated layer ofnickel over said chromium and gold; and a plated layer of platinum oversaid nickel layer; wherein said superalloy has a thickness in the rangeof about 5 to 8 thousands of an inch; wherein said layers of chromiumand gold have a thickness in the range of about 0.0012 to 0.0032thousands of an inch and about 0.02 to 0.04 thousands of an inch,respectively; wherein said layer of nickel has a thickness in the rangeof about −1.2 to 1.8 thousands of an inch; wherein said layer ofplatinum has a thickness in the range of about 0.4 to 0.7 thousands ofan inch; said nickel layer being diffused into said platinum layer; anda load distribution layer of nickel oxide formed from oxidation of saiddiffused nickel.
 10. A ceramic blade for turbines, the blade having acompliant layer coating attachment comprising: a single crystal nickelbase superalloy; evaporated layers of chromium and gold on one side ofsaid superalloy; a plated layer of nickel over said chromium and gold; aplated layer of platinum over said nickel layer; said nickel layer beingdiffused into said platinum layer; and a load distribution layer ofnickel oxide formed from oxidation of said diffused nickel.
 11. Theblade coating attachment of claim recited in claim 10 wherein saidsuperalloy has a thickness in the range of about 5 to 8 thousands of aninch.
 12. The blade coating attachment of claim recited in claim 10wherein said layers of chromium and gold have a thickness in the rangeof about 0.0012 to 0.0032 thousands of an inch and about 0.02 to 0.04thousands of an inch, respectively.
 13. The blade coating attachment ofclaim recited in claim 10 wherein said layer of nickel has a thicknessin the range of about 1.2 to 1.8 thousands of an inch.
 14. The bladecoating attachment of claim recited in claim 10 wherein said layer ofplatinum has a thickness in the range of about 0.4 to 0.7 thousands ofan inch.